INDUSTRIAL TRAINING REPORT:

AT

LAFARGE MALAYAN CEMENT

LANGKAWI PLANT

BY

MUHAMMAD FAHMI BIN ABD TALIB

(ME 083597)

COLLEGE OF ENGINEERING

UNIVERSITI TENAGA NASIONAL

START DATE: 25 JANUARY 2012

END DATE: 18 APRIL 2012

MUHAMMAD FAHMI BIN ABD TALIB

(ME 083597)

COLLEGE OF ENGINEERING

i

ACKNOWLEDGEMENT

Special thanks to my helpful supervisor, Ir. Dr. Azmi Ahmad. The supervision and

support that he gave truly helps the progression and smoothness of my internship

program. The cooperation is much indeed appreciation.

My grateful thanks also to Lafarge Malayan Cement Plant Manager, Mr. E. R. Kim in

giving me an opportunity to work in his plant and also for both host supervisors, Mr.

Ibrahim bin Muhammad and Puan Nor Ain Yahya. A big contribution and hard worked

from both of you during the 12 weeks is very great indeed. All knowledge obtained during

the internship program would be nothing without the enthusiasm and passion from both of

you. Besides, the internship program also make me realized the value of working together

as a team and as a new experience in working environment, which challenges us each

minute.

Not forgotten teammates from both Maintenance and Process Department especially to

Mr. Abu Yamin, Mr. Rusli and Mr. Rafie for their kindness on guiding me throughout my

internship there. The whole program really brought us together to appreciate the true

value of friendship and respect of each other.

Great deals appreciated also to College of Engineering. The well planned and systemic

procedures plus some useful advices help me in doing internship Lafarge Malayan

Cement who is the biggest cement producer in the world.

Last but not least, thanks to Lafarge Malayan Cement trainees from Kolej Polytech Mara

Alor Setar (POLISAS) for their kindness. Discussions and memorable activities that we

had done together give me enjoyment while completing this internship program.

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ABSTRACT

University Tenaga Nasional (UNITEN) offers an Industrial Training Program

especially for third year students as a requirement for them to complete their engineering

course in UNITEN Putrajaya campus. With 4 credits hours, students will be allocated in a

hosted company decided by them in order to gain real life working experience.

Throughout the 12 weeks industrial training, the students’ performance will be fully

monitored by host supervisor and will be guided by UNITEN selected lecturer as their

supervisors.

Industrial Training Program is conducted with objectives to give opportunities for

students to gain their own real life experience before entering actual working life.

Besides, this could be an opportunity for them to gain as much knowledge as they could

in the things that they have learnt before. In order to join an industrial training, students

are needed to attend a Safety and Health briefing organized by CIDB.

The industrial training could be a good starting point for students to gain their

knowledge in the field that they want next preparing themselves with the real working life

that they will experience soon. Hopefully, this report will be used as a reference for

students and lecturers who interested in Cement Production.

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Industrial Training Objectives

Industrial training has its own objectives for students to work at any company or

institution in order to fulfill the education syllabus requirements. The main objective of

this industrial training is to give opportunities for students to gain experience and to be

exposed in real working life, so that they could make a good preparation before starting

their job after graduation. This opportunity is a one of the future challenges to practice

their ability to do a given job or task as well as possible.

This training also gives opportunity for students to know the association between

theories studied with real practicalities practice and skill in career world. Nevertheless the

other purpose of the Industrial Training is to provide exposure for students on practical

engineering fields. Through this exposure, students will have better understanding of

engineering practice in general and sense of frequent and possible problems.

Industrial training also makes students to be high characteristics, proactive,

dedicated, in discipline, dynamic, work in team work and trust. As we know, during

training students is under pressure with many problems and new environment. So that,

students should know how to handle it with the appropriate way and also try to solve all

the problems with their best.

Widen relationship and social intercourse nicely with current employee to

improve team work spirit. At the same time, student also exposed up-to-date with

technology such as computer system and technology used inside construction sector and

maintenance. Indirectly it does also improve knowledge of the technology.

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WEEKLY TRAINING OVERVIEW

Week 1

I reached the Lafarge Malayan Cement Langkawi Plant and reported to HRA Executive,

Mr Azis Bahari. I was given all the Personal Protective Equipment (PPE) like working

attire, boots, helmets and safety goggle in order to ensure my safety throughout the

industrial training there. After that, some interpersonal interviews between HR Manager,

Mr Syafik and I was done. Throughout this week, I need to attend the Familiar Program

organized by Human Resource where this program had introduced me the overall

information regarding Lafarge Plant. At the end of this program, I had been given a

chance to decide which department I would like to be undertrained. I decided that I will

be undertrained by Maintenance Department for the first 1 and the half month and at the

Process Department for the other 1 and the half month.

Week 2

I was assigned to follow the Quarry Section Supervisor, Mr. Abu Yamin for this whole

week. For the first day, I was brought to limestone and clay quarry in order to familiarize

me with their daily routine. By using a pickup, I was brought to the limestone crushers

(1200TPH and 850TPH). There, I had been explained and shown the mechanism of a clay

crusher and how the process of crushing the limestone. Moreover, I also had been

introduced to the limestone transportation, belt conveyor. For the second and the third

day, I joined the execution team where a serious problem regarding the clay crusher had

been reported. The clay crusher experienced some blockage at the chute thus causing the

clay did not been crushed to the respective sizes properly. In order to overcome the

problem, the chute was enlarged. The execution team took three days for this project.

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Week 3

For the week 3, I was sent to the cement mill section in order to learn the last stage of

cement production. At the early of the week, I was brought to see the Dust Collector

System where this system is very important in maintaining the dust emission. Poor Dust

Collector results high level dust emission thus polluting the environment. In that week

also, I involved in replacing the outer slotted plate for Cement Mill 4. Moreover, I also

attended a safety briefing organized by Safety Department on Procedures Working in

Hole.

Week 4

I had been brought by Mr. Rusli to see a problem occurred at Cement Mill 4 involving the

leakage of shell liners. In the observation, we conclude that the leakage did not caused by

shell liner but the bolts that loosen. Thus, process of retighten the bolts had been done.

Together with the process was a Preventive Maintenance (PM). For this PM, iching had

been done in order to identify the condition of the shell liners and the broken shell liners

were replaced by the new one. Throughout this week also, I was given a project by a

Young Engineer, Mr. Mahzuz where this project will be ran in July. It was a joint project

leaded by Mr. Mahzuz and this project involves the Sealing Air Fan for Cement Mill 4.

Week 5

In this week I was undertrained by Raw Mill Section Young Engineer, Mr. Joshter. I was

assigned to follow an Inspector to do a Mechanical Vibration Test at Raw Mill 2. In this

test, we had identified a problem in a gearbox. From the data obtained high level of

vibrations occurred at the bearing of the gearbox. A report had been issued to

Maintenance team. Besides joining the Raw Mill Section team, the Sealing Air Fan

Project still ran by schedule. I was assigned by Mr. Mahzuz to calculate the volume of air

vi

in the lubrication system and determine what type of fan suitable for this project. For this

assignment, I managed to obtain 4.1096 m3 of air needed and this volume was close to the

value provided by a consultant company.

Week 6

This week was the first week I was undertrained by Process Department. I was asked by

Human Resources Executive, Mr. Azis Bahari to report myself to Puan Nor Ain who will

be my supervisor for the next one and the half month. For the first day in Process

Department, I was brought by Mr. Zakrullah, a Young Engineer to see the Raw Mill

section in term of a Process Engineer view.

Week 7

In this entire week, few programs had been successfully done by Human Resource and

Process department. The programs were Quality Award program and Kill-A-Watt

program. Besides the launched of both programs, I also had learned on how to calculate

the fan performance curve for Line 2. Last but not least, I also helped Process engineers

in determining the wet bulb temperature at Raw Mil 2 (RM2).

Week 8

Some inspections were done in order to find leakages that occur in Silo Compressors and

Coal Mill 2 (COM2). The inspections were done in order to find the source of leakages

that affect the entire process before. In this week also I attended a safety briefing on the

procedure and rules when working a confined space.

Week 9

Week 9 was the week that I learned a lot on tests that had been done by Quality Control

Department. The tests were Residue test for both Normal Blaine and High Blaine and

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Sieve test. Both tests are done daily in order to ensure cement that produced is under the

required quality of cement needed by plant. I also helped one of the teammate in Process

department in sealing leakage at hot ducting in Raw Mill 2.

Week 10

Lafarge Malayan Cement had given me a one week holiday so that I can take some rest at

home with my family. This holiday was given to all trainees there. In order to apply it, I

was needed to fill up a form where the location I went for the whole week and days of

holiday taken were asked. The form then was submitted to Human Resource Department

for their record.

Week 11

Inspections and fire drill had been done in this week. 2 inspections were done involving

the dust collector system (purging air) and Grinding Mill at Coal Mill 2 (COM 2). Other

than that, a preventive maintenance and a fire drill on Confined Space were done.

Week 12

In took almost the entire week to do projects given to me. I was briefed by Mr.

Zakhrullah, a young engineer from Process Department on my first project which was to

trace the pressure vessels available in LMC Langkawi Plant started by Cement Mill

section. To trace the vessels, I joined some inspectors to trace each of the pressure

vessels. Through the visit, I was able to note the location, serial number and conditions of

the pressure vessels. At the end of the week, I was able to draw a complete drawing for

cement mill I presented it to the process engineers.

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Table of Contents

Acknowledgement i

Abstract ii

Weekly Training Overview iv

Table of Contents viii

Company Profiles

1.1 Lafarge Cement 1

1.1.1 History of Lafarge Cement 1

1.1.2 Lafarge Cement Timeline 2

1.2 Lafarge Malayan Cement 14

1.2.1 History of Lafarge Malayan Cement 14

1.2.2 Lafarge Malayan Cement Timeline 15

1.3 LMC Langkawi Plant Overview 21

1.3.1 Location of LMC Langkawi 21

1.3.2 Organizational Structure of LMC Langkawi 23

1.3.3 Technical Data in LMC Langkawi 24

1.3.4 LMC Langkawi Plant Visions and Missions 25

1.3.5 Components of LMC Langkawi 26

1.3.6 Products of LMC Langkawi 28

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Manufacturing Process of Cement

2.1 What is Cement? 31

2.2 Process 33

2.2.1 Raw Material Preparation 33

2.2.2 Grinding and Storage of Raw Material 35

2.2.3 The Firing of Raw Material 36

2.2.4 Storage and Grinding of Raw Material 38

2.2.5 Packaging and Shipment 40

2.3 Summary 41

Crushers

3.1 Introduction 43

3.2 Type of Crusher Used in LMC Langkawi 44

3.2.1 Jaw Crusher 44

3.2.2 Roller Crusher 47

3.2.3 Hammer Crusher 48

3.3 Preventive Maintenances 50

3.3.1 Modify Scraper Outlet Chute of Jaw Crusher 50

3.3.2 Change the Teeth of Jaw Crusher 52

Grinding Mill

4.1 Introduction 53

4.2 Vertical Mill (Roller Mill) 54

4.2.1 Introduction 54

4.2.2 Mechanism 55

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4.3 Ball Mill (Tube Mill) 56

4.3.1 Introduction 56

4.3.2 Mechanism 57

4.4 Grinding Aid 58

4.5 Preventive Maintenances 59

4.5.1 Outer Slotted Plate Renewed 59

4.5.2 Feed End Liner and Shell Liner Retighten 60

4.5.3 Alignment Motor for Driver Raw Mill 2 (RM2) 61

4.5.4 Taking Flow Rate Reading of Grinding Aid for Cement Mill 3 62

Dust Collector

5.1 Introduction 63

5.2 Type of Dust Collectors Used in LMC Langkawi 64

5.2.1 Gravity Settling Chamber 64

5.2.2 Cyclones 65

5.2.3 Multicyclones 66

5.2.4 Fabric Filters 67

5.2.5 Electrostatic Precipitators 69

5.3 Preventive Maintenances 70

5.3.1 Change the Air Bag Filter for Cement Mill 3 70

5.3.2 Inspection of COM 2 Dust Collector System Purging Air 71

Preheater

6.1 Introduction 72

6.2 Mechanism 73

6.3 Preventive Maintenances 76

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6.3.1 Measuring Temperature and Pressure Reading 76

6.3.2 Coating Leakage at Single Flap Damper, Hot Meal Duct 77

6.3.3 Take Pressure, Temperature and Air Flow Reading of Kiln 78

6.3.4 Measuring the Wet Bulb Temperature 79

Quality Control

7.1 Introduction 80

7.2 Hard Grain Index 81

7.3 Sieve Test 82

7.4 Residue Test 83

7.5 Drop Test 84

Projects

8.1 Project 1: Sealing Air Fan for Cement Mill 4 (CM4) 85

8.1.1 Background 85

8.1.2 Objective 87

8.1.3 Expected Benefits 87

8.1.4 Cost Justification 87

8.1.5 Resource Requirements 88

8.2 Project 2: Tracing Pressure Vessel Tank in Cement Mill Section 89

8.2.1 Introduction 89

8.2.2 Problem 90

8.2.3 Solution 90

8.2.4 Completed Drawing 91

8.3 Measuring the Actual Fan Performance Curve for LK1 and LK2 92

8.3.1 LK2 – Raw Mill EP Fan 93

xii

8.3.2 LK2 – Cooler Exhaust Fan 94

8.3.3 DOPOL Waste Gas Fan 95

8.3.4 Raw Mill Fan 96

Discussions

9.1 Safety at Workplace 97

9.1.1 Personal Protective Equipment (PPE) 99

9.1.2 Safety Reporting System (SRS) 100

9.2 Environmental Issue 101

9.2.1 Lafarge Group Policies 101

9.2.2 Lafarge Malayan Cement Initiatives 103

9.2.2.1 Biomass to Energy 103

9.2.2.2 Lafarge Roofing 105

Conclusion 107

References 108

Appendices 111

1

CHAPTER 1: COMPANY PROFILES

1.1 LAFARGE CEMENT

1.1.1 HISTORY OF LAFARGE CEMENT

Lafarge is a French industrial company specializing in four major products which are

cement, construction aggregates, concretes and gypsum wallboard. The Lafarge Cement

began operations in 1833 with lime operation in France leaded by Auguste Pavin de

Lafarge. Through the numerous acquisitions of lime and cement industries throughout the

countries, Lafarge became France’s largest cement producer by the late 1930s.

The company first expanded internationally in 1864 with the supply of lime for

construction of the Suez Canal. International expansion continued in the early twentieth

century when operations began in North Africa, United Kingdom, Brazil and Canada.

Through the 1981 acquisition of General Portland Inc., Lafarge became one of the largest

cement manufacturers in North America. Further expansion of Lafarge continued with the

purchase of Blue Circle Industries in 2001 next took on acquisitions around the

Mediterranean Basin, Eastern Europe, the Middle East and Asia. By the expansion

Lafarge has become the joint leader in the worldwide cement industry, with production

facilities in almost 51 countries.

The aggregates and concrete business, now operating in 29 countries, made a significant

leap in 1997 with the acquisition of Redland plc, one of the principal manufacturers of

aggregates and concrete worldwide at the time.

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1.1.2 LAFARGE CEMENT TIMELINE

1833

The Beginning

The story of the world leader in building materials began in the Ardèche region at a place

called “Lafarge”, which means “the forge”, near the village of Teil. Joseph-Auguste

Pavin de Lafarge began regular extraction operations in the limestone quarries. He had 2

major advantages which are geological and geographical. The geographical means the

limestone of the region is of excellent quality and can be used to replace mortar and the

Rhone River makes in relatively easy to transport goods. Joseph’s two sons, Eduord and

Lèon developed the family company, which then became known as “Lafarge Frères”

which means Lafarge Brothers in 1848.

1864

First major project: the Suez Canal

Lafarge won the “contract of the century” in Egypt. 200,000 tons of hydraulic lime

delivered in wooden barrels, were needed to build the piers of Suez canal. Although its

production capacity was limited to just 20 kilns, which produced 50,000 tons per year,

Lafarge rose to the challenge. The canal was inaugurated on 17 November 1869,

connecting the Mediterranean Sea to the Red Sea.

1866

First operations in Algeria and development in North Africa

The Suez Canal contract, the company’s first success in the Mediterranean basin, was the

prelude to expansion and the opening of commercial offices in Marseilles, Sète, Tunis

3

and Algiers. Within a few years, the Group had become the leading producer of Portland

Cement in Algeria.

1887

Creation of the world’s first research laboratory specialized in cement

On the back of its commercial success, Lafarge opened a research laboratory near Teil,

France. This laboratory was the first in the world to specialize in cement. The gifted

scientists working there placed the laboratory at the forefront of technological progress.

To this day, Lafarge works with the most talented research teams. Physical, chemical and

mechanical research allows Lafarge to retain its position as the leader in building

materials and respond ever more closely to customer requirements.

1889

Social policy rewarded at the Universal Exhibition

From the outset, Lafarge has paid close attention to the living and working conditions of

its employees and has invested in facilities ranging from dormitories, canteens and

hospitals to schools, gardens and rent-controlled housing. The Group’s social policy was

rewarded with a gold medal at the Universal Exhibition. Lafarge received this award

again in 1900.

1899-1906

Elaboration of the “revolving extinction technique”

Lafarge’s teams developed the “revolving roller extinction technique”, an innovative

procedure used to create white lime, maritime lime and extra-white cement. The first

buildings made with these Lafarge products were the New York Stock Exchange (cut

4

stone with white cement joints) and prestigious buildings in the Mediterranean region

including the pier in Venice, the port of Algiers and Corinth canal.

1908

Ciment Fondu®, resistant to external forces and high temperatures

Lafarge research director Jules Bied filed a patent for Ciment Fondu®, obtained by

mixing limestone and bauxite. This cement quickly acquired an excellent reputation

thanks to its many properties, notably rapid hardening and resistance to corrosion and

high temperatures. It was put to a range of uses and can be found in the Paris metro, on

oil rigs, in equipment for the world’s leading steel manufacturers and more recently, in

the launch pad for the Ariane rocket in Kourou, French Guiana. Ciment Fondu® is the

base ingredient for a number of innovative products including special mortars and

refractory concretes.

1921

First patent for white cement

During the fabrication process for white cement, clay is replaced by kaolin, which

contains low quantities of iron oxide. White cement has the same properties as

comparable grey cement but offers additional esthetic qualities. White cement is still used

today.

1930

First quarry rehabilitation in Draveil, France

Lafarge has long been aware of the environmental impact of its extraction activities. In

1930, the Group carried out its first quarry rehabilitation project. Today, the Group plans

5

the rehabilitation of each site before it begins extraction. An environmental impact study,

carried out in advance of operations, identifies all measures that will be required to

protect the environment, biodiversity and local communities.

1931

Diversification into gypsum, the production of gypsum powder

In 1931, the Group acquired “Gypses et Plâtres de France”, a company based in the South

France that owned a number of Gypsum quarries. This acquisition marked Lafarge’s

entry into a promising market later it became the 3rd

largest producer of gypsum in the

world.

1947

The leading cement producer in France and North Africa

Throughout the first part of the 20th

century, the Lafarge lime and cement company

continued to develop by acquiring companies across France. After the Second World

War, Lafarge consolidated its position as the leading cement producer in France and

International development increased while greater demand for building materials saw

production double in just 10 years.

1956

The first cement plant in North America and the creation of Lafarge Cement of North

America (LCNA)

Lafarge built its first cement plant in North America at Richmond in western Canada. It

was a bold move to locate a plant 10,000 km and 24 hours by plane from France.

6

1959

First operations in Brazil

Lafarge acquired a stake in Cominci, a Brazillian company, and built its first cement plant

in Brazil at Matozhinos. This plant was the first to produce the famous “Campeâo” brand

of cement.

1970

Creation of Canada Cement Ltd. (CCL), the country’s leading cement producer

1970 saw the merger between Lafarge Cement of North America (LCNA), founded in

1956, and Canada’s largest cement producer, Canada Cement Company which had been

founded in 1909. The new company was called Canada Cement Lafarge Ltd. (CCL)

became the largest cement producer in Canada with 11 plants.

1971

Agreement with the French Ministry for the Environment on dust emissions

Since 1971, Lafarge has been taking active steps to reduce dust emissions from its cement

plants. The Group does more than simply comply with regulations and the equipment and

processes used in plants, such as chimney evacuation filters are constantly being

improved through the use of new technologies.

1972

Development of superplasticizers and modernization of the Group

Following the oil crisis, the Group was reorganized and the Lafarge holding company was

created. New management methods and more effective industrial processes allowed the

Group to pursue renewed growth. Lafarge’s research and development team (R&D)

7

developed water-reducing admixtures also known as “superplasticizers” which create a

fluid concrete without the addition of water.

1974

First use of industrial waste as an alternative fuel

In the mid-70s, as petrol prices soared, Lafarge realized that industrial and agricultural

waste products such as coffee pods, rice husks, tires, solvents and bone meal could be

used to add value in its processes. This industrial ecology approach safely reduces the use

of fossil fuels, diversifies energy sources and provides a service to communities by

recycling waste. It also reduces CO2 emissions which is particularly important given that

the cement industry is responsible for 5% global emissions.

1977

Publication of the Group’s Principles of Action

Lafarge’s humanist traditions, passed down the generations since the company was

founded, inspired the Group’s Principle of Action. As Olivier Lecerf, Chairman from

1974 to 1989, said “We try to manage by serving rather than by dominating. The true

legitimacy of a leader lies in his capacity to serve.” The Principles of Action are a set of

humanist values and commitments shared by all employees. They incorporated a vision of

becoming the undisputed market leader, commitments to stakeholders and the Lafarge

Way, which is a code of conduct that encourages individual success within a multi-local

organization.

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1980

Lafarge achieves leadership on the North American cement market – Perfection of

high performance concretes

The newly-created Lafarge Coppèe Group, born of the merger between Lafarge and

Coppèe, became North America’s leading cement producer. The Groups’s workforce

increased from 12,000 to 17,000. The following year, Lafarge consolidated its position in

North America when it acquired a majority shareholding in General Portland, the 3rd

largest cement producer in the world.

1985

First operations in Cameroon and sub-Saharan Africa

Lafarge took its first steps in sub-Saharan Africa in 1985, when it opened a site in

Cameroon. Lafarge now has activities in 10 countries in sub-Saharan Africa.

1995

Sustainable development at the heart of the Group'

Lafarge implemented its first recycling programs which was production waste was used

as an alternative to standard raw materials and fuels at all industrial sites where this was

technically possible. The Group published its environmental policy and made

commitments regarding the conservation of extraction sites. In the 1995 also Lafarge

launched its first employee stock option plan to allow employees to share the Group’s

financial success and encourage a sense of community. This operation has been repeated

regularly and enjoys growing success.

9

1997

Acquisition of Redland: a new business portfolio and further consolidation

The acquisition of Redland, a British group strengthened Lafarge’s positions in

aggregates and concrete, turned the Group into the leader in building materials in North

America and allowed Lafarge to enter the roofing sector.

1998

First operations in India and South Korea

Continuing its growth strategy in Asia, Lafarge acquired 2 plasterboard factories in South

Korea, close to the town of Busan. The South Korea plasterboard market is the second

largest in the region and offers excellent potential for further growth. Lafarge also entered

the Indian cement market by purchasing the cement division of Tata Iron & Steel

Company Ltd (TISCO), India’s leading steel manufacturer. This acquisition gave the

Group a strong presence on the market in western Bengal and an efficient industrial

operation in the form of a cement plant and a grinding plant.

2000

A turning point: acquisitions, new product launches and partnerships

Lafarge and WWF, the world’s largest environmental protection organization, signed a 5-

year agreement as part of the “Conservation Partner” program. Besides, the merger

between Lafarge’s Aggregates Business and that of the Warren Paving & Materials

Group saw Lafarge became one of the leading aggregates producers on the North

American market.

10

2001

Lafarge, the world’s leading cement producer, targets sustainable growth

With the acquisition of Blue Circe, the Group became the world’s leading cement

producer and strengthened its position in emerging markets. Lafarge’s first sustainability

report received an award for the private sector company which provides the best

environmental communication tools.

2002

Framework agreement with the CNRS and the launch of PLAtecTM

Lafarge and the French National Center for Scientific Research (CNRS), Europe’s

leading research organization, signed a framework agreement to reinforce their

cooperation. Besides, the Group launched PLAtecTM, a range of made-to-measure

plasterboard solutions which has been used in interior design projects from government

building in Vaucluse to the headquarters of Virgin, designed by Renzo Piano.

2003

Signature of the UN Global Compact, creation of the Stakeholder Panel and further

efforts in the fight against AIDS

Lafarge signed a 5-year partnership agreement with Care, a non-governmental

organization, to fight against AIDS. The Group created a stakeholder panel to gain an

external perspective on its activities and strategy.

11

2004

Expansion in emerging markets, the launch of SignaTM, humanitarian aid,

sponsorship

The Group developed its Businesses in emerging countries by building new plants in Asia

(Thailand, India, Cambodia, etc.), by consolidating its position in Korea, by expanding its

cement capacities in North Africa and Eastern Europe. Following the tsunami of

December 2004, Lafarge acted quickly to bring emergency aid to employees and their

families.

2005

Recognition for the Group’s sustainable development activities – Increased production

capacities

Through a joint venture, Lafarge doubled its production capacity in China and became the

third largest cement producer in the country. It also invested 300 million euros to expand

the production capacities of its Gypsum Business. Lafarge ranked among the 100 best

performing multinationals in terms of sustainable development, and signed an agreement

on Group social responsibility and international social relations with three international

trade unions.

2006

Bruno Lafont and the Excellence 2008 Plan – Commercial launch of Sensium® -

Launch of the Hypergreen concept

Bruno Lafont was appointed as CEO of the Group and launched the Excellence 2008

strategic plan. The program will improve industrial performance, consolidate positions on

emerging markets and drive further action on sustainable development. Lafarge

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purchased Lafarge North America minority shares and became the leader in North

America across all of its Businesses.

2007

Divestment of the Roofing Business, focus on sustainable growth, launch of 2

concretes with high added value

Lafarge divested its Roofing Business to the PAI partners investment fund to concentrate

on its core activities. The Group expanded its research center, adding a new experimental

concrete plant that allows researchers to test laboratory research results in real time and

on an industrial scale.

2008

Acquisition of Orascom Cement, the leading cement group in the Middle East and the

Mediterranean Basin

This operation is a decisive acceleration of the Group’s strategy in fast-growing, highly

profitable emerging markets. Orascom cement is located in high-potential markets, with

number-one positions in the key markets of Egypt, Algeria, United Arabs Emirates and

Iraq. Its geographical presence is highly complementary with Lafarge’s emerging markets

portfolio.

2009

Growth in emerging markets – Concrete innovation

Lafarge continues to grow in emerging countries in Ecuador, Nigeria and Iraq. Innovation

is in the spotlight with the launch of Thermedia® 0.6B, a new generation of insulating

concretes.

13

2010

Innovation strategy – Shanghai World Expo – Strengthening business in Brazil and

Central Europe

Lafarge accelerates its innovation strategy and introduces Aether – a project aiming at

reducing CO2 footprint. In additions, Lafarge strengthens its presence in Brazil following

the sale of its Cimpor stake to Votorantim and becomes one of the three main cement

operators in the country. Lafarge and STRABAG, Central and Eastern Europe’s largest

construction company then create a holding company located in Austria.

2011

Significant divestment and new organization

Lafarge and Anglo American announce the creation of a leading UK construction

materials company. Lafarge also presents a new organization project more agile and

responsive, focused on its markets and its clients.

14

1.2 LAFARGE MALAYAN CEMENT

1.2.1 HISTORY OF LAFARGE MALAYAN CEMENT

Lafarge Malayan Cement Bhd (formerly known as Malayan Cement Bhd) is the producer

of cement in Malaysia with plants strategically located in Rawang, Kanthan, Langkawi

and Pasir Gudang in Peninsular Malaysia. In addition, it is the owner and operator of a

cement grinding plant and a bulk import terminal in Singapore.

The Group sells cement and other related building materials in Malaysia and Singapore.

The acquisition of the operating companies and a majority interest in Kedah Cement

Holdings Bhd in 1999 transformed the company into Malaysia’s largest cement producer

with an increased presence in Singapore.

Being a member of the Lafarge Group, the company is able to draw from an even wider

international base of experience and technical expertise and a broader international

trading network.

On 30 July 2003, the company unveiled its proposal for an internal reorganization of the

Group’s corporate structure of its Singapore subsidiaries, with the intent of streamlining

its holdings in its various subsidiaries under one Singapore incorporated company

wholly-owned by Lafarge Malayan Cement (LMC)

15

1.2.2 LAFARGE MALAYAN CEMENT TIMELINE

1950

Incorporation of Malayan Cement Berhad (now known as Lafarge Malayan Cement Bhd)

as a subsidiary of Blue Circle Industries PLC, United Kingdom.

1953

Establishment of Rawang Works, Malaysia’s first cement plant. (Rawang Kiln No.1-

110,000 tonnes per annum)

1958

Commisioning of Rawang Kiln No. 2 (190,000 tonnes per annum)

1961

Malayan Cement Berhad was listed in the Kuala Lumpur Stock Exchange Berhad on 17

March 1961.

1964

Opening of Kanthan Works by Pan Malaysia Cement Works Bhd (PMCW).

1965

Commisioning of Kanthan Kiln No. 2 (190,000 tonnes per annum). Opening of a grinding

plant in Singapore by Pan Malaysia Cement Works Singapore (PMCWS)).

16

1967

Merger of cement operations with PMCW and the formation of Associated Pan Malaysia

Cement Sdn Bhd. Also acquired 50% stake in PMCWS.

1980

Commisioning of Rawang Kiln No. 3 (1,200,000 tonnes per annum). Incorporation of

Supermix Concrete Pte Ltd (SPMS).

1983

Incorporation of Supermix Concrete (Malaysia) Sdn Bhd (SPMM)

1984

Kedah Cement Sdn Bhd (now known as Lafarge Cement Sdn Bhd) commissioned

Langkawi Plant.

1985

Commisioning of Kanthan Kiln No.3 (800,000 tonnes per annum).

1989

The company launches its first differentiated bulk product, Mascrete.

1992-1993

Uprating of Rawang Kiln No. 3 and Kanthan Kiln No. 3 to 1.5 and 1.0 million tons per

annum.

17

1995

Rawang Plant becomes the first location within the Group and the first cement plant in

Malaysia to be awarded the ISO 9002 (now changed to ISO 9001:2000) certification.

Kanthan Plant received the same certification about three months later.

1997

Southern Cement Industries Sdn Bhd (SCI) commissioned its grinding plant with a rated

capacity of 770,000 tons per annum in Pasir Gudang, Johor. Commisioning of Bulk

Import Terminal with silo capacity of 55,000 tons in Jurong Port, Singapore to replace

PMCWS grinding facility.

1998

Commisioning of Kanthan Kiln No. 4 (1,800,000 tonnes per annum) Acquisition of the

remaining 50% stake in APMC). Rawang and Kanthan Plants were awarded the ISO

14001 certification, making us the first cement company in Malaysia to achieve this

certification.

1999

Acquisition of Kedah Cement and merger between APMC and Kedah Cement.

2000

Opening of a dry-mix cementitious product plant in Tuas, Singapore. We become the first

cement company to be awarded the OHSAS 18001 certification when Rawang Plant

receives the certification on 8 December 2000 closely followed by Kanthan Plant on 15

December.

18

2001

Becoming part of Lafarge Group following Lafarge’s acquisition of Blue Circle. SPMM

acquired Pengkalan Concrete and spread its wings to East Malaysia. The company

celebrated the launch of the first fly ash bag cement, Phoenix. Besides, Malayan Cement

was awarded the Corporate Awards 2001, Sectorial Award, Main Board – Industrial

Products awarded by the Kuala Lumpur Stock Exchange.

2002

Malayan Cement launched a new corporate identity which reflects its membership in the

Lafarge Group. In addition, Malaya Cement was awarded the Corporate Awards 2002,

Merit Award, Main Board – Industrial Products, Kuala Lumpur Stock Exchange.

2003

Company name officially changed from Malayan Cement Berhad to Lafarge Malayan

Cement Berhad to better reflect its corporate identity as a member of the Lafarge Group.

Lafarge Malayan Cement was recognized as a Leader – Construction Sector by Malaysia

1000, Malaysia’s top corporate directory.

2005

We secured a long-term contract with Tanjung Bin power plant for the exclusive supply

of all their fly ash production. Lafarge also launch the Logistics Safety Conference with

the objective of increasing awareness on road safety amongst the company’s transporters

and drivers towards achieving zero accident in loading and transportation. Lafarge Young

Engineers Programme also had been launched where fresh graduates from local

19

universities are recruited and enrolled annually in a cement professional development

programme to nurture them into skilled engineers.

2006

Launch of a new differentiated bulk product, Mascrete Pro and the Industrial Safety

Conference in order to instill greater safety awareness amongst the company’s members.

Besides the opening of the residential housing area, Desa Kuala Garing, built and

contributed by LMC to relocate 124 squatters in Rawang.

2007

An annual production record of 3 million tons of clinker by Kanthan Plant. Pasir Gudang

Plant launched its first Pulverized Fly Ash (PFA) blended cement.

2008

Lafarge Malayan Cement was honored with the Industry excellence Award

(Construction) and Merdeka Corporate Award by Malaysia 1000, Malaysia’s top

corporate directory.

2009

Lafarge Malayan Cement was selected as one of the twenty finalists (Marketplace

dimension) in the StarBiz-ICR Malaysia Corporate Responsibility Awards. The award

focuses on how well companies demonstrate their understanding of Corporate

Responsibility throughout the business operations.

20

2010

Lafarge Malayan Cement was honored with “Technology Innovation Award for

Sustainable Production of Cement” by Frost & Sullivan Green Excellence Awards on 9

June for demonstrating its firm commitment to a continuous focus on reducing the

decency on finite resources and resolving to reduce the impact for climate change and

overall ecological footprint. LMC also was honored with a plaque by StarBiz ICR

Malaysia Corporate Responsibility for being one of the finalists in the segment above

RM1 billion market capitalizations. Lafarge Malayan Cement also was placed 11th

for

Best Corporate Governance Company in Malaysia by Finance Asia, a Hong Kong-based

publication reporting on Asia’s financial and capital markets.

2011

Lafarge Malayan Cement receives the Singapore Green Building Product certification for

Mascrete LH cement and Phoenix cement by the Singapore Green Building Council.

Moreover, LMC also has been awarded an Innovative Award for Sustainable Production

of Building Materials by the Malaysian French Chamber of Commerce & Industry on 24

June 2011. Plus, Lafarge Malayan Cement was recognized as a sustainable development

leader and was presented the “Enterprise Governance Award 2011 for Green initiative”

by The Malaysia Business and the Chartered Institute of Management Accountants

Malaysia on 27 September 2011 and short while later was awarded the SIRIM Eco-Label

for Phoenix and Mascrete LH on November 2011.

21

1.3 LAFARGE MALAYAN CEMENT LANGKAWI PLANT OVERVIEW

1.3.1 LOCATION OF LAFARGE MALAYAN CEMENT LANGKAWI PLANT

Figure 1.1: Langkawi Plant Layout

Figure 1.2: Location of LMC Langkawi

22

Figure 1.3: Plant Layout of LMC Langkawi

23

1.3.2 ORGANIZATIONAL STRUCTURE

24

1.3.3 TECHNICAL DATA

Lafarge Malayan Cement Langkawi Plant (LMC) formerly known as Kedah Cement Sdn

Bhd is one of the plant built in Malaysia. First built by the 4th

former Prime Minister, Tun

Mahathir Mohamad in 1981, the plant had been named with Kedah Malayan Cement

however the plant had been acquainted by Blue Circle, a UK cement producer in 1999.

The Blue Circle has been acquainted by Lafarge Cement in 2001 short while later. Till

now, the plant remains organized by Lafarge Malayan Cement centered at Petaling Jaya

and supervised by the board of directors in Paris, France.

With the area of 1162.25 acres and 398 employees, the Lafarge Malayan Cement

Langkawi Plant produces approximately 3.38 million of cement per annum thus

becoming the largest producers and the only exporter of cement products in Peninsular of

Malaysia to Singapore, Bangladesh, Myanmar, Hong Kong, Sri Lanka, Mauritius Nigeria

and Australia.

The plant operates with 2 lines called line 1 (LK1) and line 2 (LK2) which use Japan

technology and German technology respectively. Technology that is used from Japan

technology is from Ishikawajima Harima Heavy Industries while for German technology

of Krupp Polysius of Germany is implemented. Each line consist of Raw Mill, Cement

Mill, Coal Mill and Preheater and these sections are monitored and ran under supervision

of Maintenance, Quality, Process and Production Department.

25

1.3.4 LMC LANGKAWI PLANT VISION AND MISSION

People Mobilization

• Succession Planning

• Retention of talents

• Follow up on IDP program

implementation and close coaching

• Front Line Supervisor development

program

Plant Mastery

• Job ownership/Core functions

competency

• Improve competency of our talent

• 5G 3S shift operation

LANGKAWI PLANT 2012 HOUSE

To achieve

total Plant Masteryfor our customer with

Safety as our way of life

•Health & Safety-cultured workforce in all the sites•Towards mastered and robust plant with sustainable improvement

•Clean and Environmental friendly plant for our employees & community

•Meeting external and internal customers expectations•Leadership through performance culture

Health & Safety

• Zero total injury

frequency rate

• Area ownership JHP

and HK

• Practice safety

interventions

• Zero environmental

infringements

• 12 hrs Safety training

• Compliance with

group standards and

advisories

• POM Compliance

• Industrial standards (LQTS, LQMS,

Power, heat to come, first 5 rules

are mandatory)

• Kiln RF => 97.13%

• Kiln PF => 93.42%

• Cement mill RF =>97.27% @

UF64.48%

• Cementitious C/K => 1.1165

• Cost ownership & control (VC

HC3,335 MJ/ton clk, Power 77.92

kwhr/Clk, grinding 51.26 kwhr, IFC

compliance 74.54 mMYR

• AF replacement 13.24%

• Maintenance project, MCI <= 1.29,

• Engg.Spares: RM53.23m, Gr.media :

RM 0.3m, Refractory: RM 0.8m

Customer Satisfaction

• OTIFIC => 92%, for

both Domestic and

Export

• Consistent

Product Quality

IQP => 95%

• Product quality

complaints =

Reduction by 50%

vs. previous year

• LP Ship loaders

RF => 96%

Plant Mastery

26

1.3.5 COMPONENTS OF LMC LANGKAWI

Human Resource Department

Create and preserve relationship between company and stakeholders.

Maintenance Department

Management

Results-driven based upon delegation with clear goals and objectives.

Execution team

o Mechanical team

Service and repair machines in plant

o Electrical team

Service and repair electrical components in plant.

Method team

o Inspection team

Maintain- in depth knowledge of equipment conditions.

o Mechanical Planner

Every actions needed in each of the project is well planned.

o Electrical Planner

Every actions needed in each of the project is well

planned.

27

Production Department

Monitoring production’s equipment ran in the plant.

Finance Department

Manage the cash flow and budget of Lafarge Malayan Cement Bhd.

Health and Safety Department

Responsible to give briefing and safety information plus ensuring the safety

procedures are followed by each of members.

Process Department

Monitor and Control each of the process took place in each section.

28

1.3.6 PRODUCTS OF LMC LANGKAWI

Ordinary Portland Cement

Ordinary Portland Cement (OPC) is the most common cement used in general concrete

construction when there is no exposure to sulphates in the soil or groundwater. The raw

materials required for the manufacture of OPC are calcareous material such as limestone

or chalk and argilaceous materials such as shale or clay. A mixture of these materials is

burnt at a high temperature of approximately 1400 0C in a rotary kiln to form clinker. The

clinker is then cooled and grounded with a requisite amount of gypsum into fine powder

known as Portland cement.

OPC is a gray coloured powder. It is capable of bonding mineral fragments into a

compact whole when mixed with water. This hydration process results in a progressive

stiffening, hardening and strength development.

Cement Products

Ordinary Portland Cement (OPC)

Phoenix

Walcrete Mascrete

Rumah

29

Portland Composite Cement (Phoenix)

PHOENIX is the brand name of specifically

blended bagged Portland-composite cement. It is

manufactured by grinding calcium sulfate as a

setting regulator with Portland Cement clinker

and other carefully selected secondary

constituents (pozzolanic materials, fly ash and other constituents permitted under BS EN

197-1:2000). There are some advantages provided by PHOENIX which are improved

compactibility, improve cohesiveness, richer mix, improved surface finish, reduced

bleeding and lastly it improves board life.

Masonry Cement (Walcrete)

Masonry Cement is an extremely versatile. It is

recommended highly for bedding and pointing

brickwork and blockwork, interior and exterior

plastering and wall finishes. It is a homogenous blend

of controlled amounts of Portland Cement, plasticizing

material and air entraining agent, inter-ground to a high

fineness to give consistent quality.

Unlike conventional mortar which is a mixture of four ingredients (i.e. Portland Cement,

lime, sand and water), WALCRETE masonry mortar requires only three ingredients,

which are WALCRETE, sand and water.

30

Its excellent water tetaining property prevents premature loss of water therefore ensuring

strong bonding, low drying shrinkage, better weather resistance, good workability, easier

handling and smoother finishing.

Portland Pulverised-Fly Ash Cement (MASCRETE LH)

MASCRETE LH is the trade name of a specially manufactured Portland Pulverized-Fuel

Ash Cement or also called Portland-fly ash cement.

Mascrete LH is manufactured by intergrinding in order to

ensure homogeneity and consistency in the quality of the

product, under an effective system of testing, control and

monitoring, confirming to requirements under SIRIM’s

Product Certification Licence MS ISO/IEC 17025.

This product is effective in reducing core temperature of

big concrete structures, also to resist Chloride and Sulfate

attack for marine situations and to improve overall concrete durability.

Portland Limestone Cement (RUMAH)

RUMAH is the brand name for multi-purpose

bagged cement suitable for any project. Compared

to the conventional OPC, its good early strength,

workability and cohesiveness make it suitable for

use in wide variety of general applications.

31

CHAPTER 2: MANUFACTURING PROCESS OF CEMENT

2.1 WHAT IS CEMENT?

Cement is a hydraulic binder and is defined as a finely ground inorganic material which,

when mixed with water, forms a paste which sets and hardens by means of hydration

reactions and processes which, after hardening retains its strength and stability even under

water. Ordinary Portland Cement (OPC) is one of several types of cement being

manufactured in Lafarge.

OPC consists mainly of Lime, Silica, Alumina, Iron and Sulphur Trioxide,

Magnesium and other Oxide elements are present in small quantities as an impurity

associated with raw materials. When cement raw materials containing the proper

proportions of the essential oxides are ground to a suitable fineness and then burnt to

incipient fusion in a kiln, chemical combination takes place, largely in the solid state

resulting in a product named clinker. This clinker, when ground to a suitable fineness,

together with a small quantity of gypsum is Portland cement. Gypsum is added at the

grinding stage to retard the settling time of finished cement.

Figure 2.1: Portland Cement

32

Figure 2.2: Langkawi Works Flow Chart

33

2.2 PROCESS

2.2.1 RAW MATERIAL PREPARATION

The raw materials required to manufacture cement are limestone, clay, iron and iron ore.

Rocks extracted from the quarry either by extraction or blasting are routed to the nearby

cement plant on a belt conveyor. Each quarry is subjected to a rehabilitation plan adopt to

its situation, including promotion of local biodiversity, creation of a touristic and

environmental park, residential, agricultural or redevelopment program.

Figure 2.3: Elements involved in the making of cement

34

Figure 2.4: Blasting process

Figure 2.5: Raw materials crushed and transported via belt conveyor

35

2.2.2 GRINDING AND STORAGE OF RAW MATERIALS

The minerals from the quarry are routed to the grinding plant where they undergo initial

milling before being reduced to a fine powder. The raw materials (80% limestone and

20% clay) are then stored in the pre-homogenization pile. Grinding produces a fine

powder called “raw meal” which is preheated and then sent to the kiln.

In the wet process, each raw material is

proportioned to meet a desired chemical

composition and fed to a rotating ball mill with

water. The raw materials are ground to a size

where the majority of the materials are less than

75 microns. Materials exiting the mill are called

"slurry" and have flow ability characteristics.

This slurry is pumped to blending tanks and homogenized to insure the chemical

composition of the slurry is correct. Following the homogenization process, the slurry is

stored in tanks until required.

In contrast with the process done in Lafarge Malayan Cement, each raw material

is grinded in a dry condition so called dry process. In the dry process, each raw material is

proportioned to meet a desired chemical composition and fed to either a rotating ball mill

or vertical roller mill. The raw materials are dried with waste process gases and ground to

a size where the majority of the materials are less than 75 microns. The dry materials

exiting either type of mill are called "kiln feed". The kiln feed is pneumatically blended to

insure the chemical composition of the kiln feed is well homogenized and then stored in

silos until required.

Figure 2.6 Raw Meal

36

Figure 2.7: Red hot clinker falls

onto the grate, cooled

by air blown from

beneath

2.2.3 THE FIRING OF RAW MATERIALS

The raw mix is fed into a preheating tower at

800°C before returning to the rotary kiln where it

is heated to a temperature of 1450°C. Combustion

causes a chemical reaction called “decarbonation”

which releases the CO2 contained in the

limestone. The fired materials take the form of

hard granules called “clinker”.

For the production of the clinker, the raw

meal which is known as kiln feed at this stage has to

be heated to a temperature of about 1450°C in the long cylindrical rotating kiln. The kiln

feed enters the system at the top of the pre-heater and fall until the lower end of the kiln.

The heat exchange occurs during this process when the hot gases from the kiln end rise up

to the top of the pre-heater. The clinker formation process is divided into four parts which

are drying, calcining, sintering and cooling. As the kiln feed moves towards the lower end

of the kiln it undergoes some successive reactions.

The red hot clinker is then discharged into the cooler, where it is quenched cooled

to around 100 degrees centigrade. The heat dissipated by the clinker is used as secondary

air for the combustion in the calciner. This hot gas is also used in the dryers at the raw

materials preparation stage. Rapid cooling of the clinker is essential as this hampers the

formation of crystals, causing part of the liquid phase to solidify as glass. The faster the

clinker cooling the smaller the crystals will be when emerging from the liquid phase.

37

Figure 2.8: Burning process occur in the

rotating kiln from 1200°C to

1400°C

Figure 2.9: Clinker that produced will be air quenched to

reduce clinker temperature from 1400°C to

120°C

38

2.2.4 STORAGE AND GRINDING OF CEMENT

Following re-cooling, the clinker is stored in silos then transformed into cement

according to production requirements. During the final manufacturing stage, gypsum is

added to the clinker, in a proportion of 3% to 5%, and the mixture finally ground. Clinker,

gypsum and grinding aid are ground together in ball mills to form the final cement

product. Fineness of the cement product, amount of gypsum added, and the amount of

process additions added are all varied to develop a desired performance in each of the

final cement products.

Figure 2.10: Elements used in clinker milling

39

Various substitute materials such as fly ash and slag can also be used in the composition

of cement. The fly ash is the residue from thermal power plant activity while for slag, it

comes from blast furnaces. Their use has the dual advantage of reducing the quantity of

clinker required next creating a wider range of cements, with qualities corresponding to

customers’ specific needs.

Figure 2.11: Clinker Silo - clinker storage before

milling process for producing cement

40

2.2.5 PACKAGING AND SHIPMENT

The cement is stored in silos before being delivered by tanker trucks or packaged into 23-

35kg bags and stacked on pallets. Various means of transport may be used according to

the local infrastructure and topography. The use of transportation methods with a low

carbon footprint is given preference wherever possible.

Tanker Truck

Ship Bulk

Ship Loader

Figure 2.12: Product is exported via trucks or

ships

41

2.3 SUMMARY

Mining the raw material

Limestone and clay are blasted from quarries by boring the rock and setting off

explosives with a negligible impact on the environment, due to modern technology

employed.

Transporting the raw material

Once the huge rocks have been fragmented, they are transported to the plant in

specialised trucks or by conveyor belt.

Crushing

The quarry stone is then delivered through conveyor belt to the crushers, where it is

reduced by crushing to chunks approximately less than 25 mm in size.

Prehomogenisation

Prehomogenisation is the proportional mix of the different types of shale, limestones, or

any other required material to form the right combination for cement.

Raw Material Storage

Each of the raw materials is transported separately to silos, where it later will be added in

specific amounts according to the particular type of cement being produced.

42

Raw Material Mill

This takes place in ball or vertical steel mill, which grinds the material through the

pressure exerted by three conical rollers which roll over a turning milling table.

Horizontal mills, inside which the material is pulverized by means of steel balls, are also

used in this phase.

Raw Meal Homogenization

This process takes place in silos equipped for obtaining a homogenous mix of the

material.

Calcination

Calcination is the core portion of the process, in which huge rotary kilns come into play.

Inside, at 1400 °C, the raw material is transformed into clinker; small, dark gray nodules

3-4 cm in diameter.

→

Cement Milling

The clinker is ground by different size steel balls while it works its way through the mill's

2 chambers, with gypsum being added to extend cement setting times.

Cement packaging and shipping

The cement is then housed in storage silos, from where it is hydraulically or mechanically

extracted and transported to facilities where it will be packaged in bags or supplied in

bulk. In either case, it can be shipped by rail car, freighter truck or ship.

43

CHAPTER 3: CRUSHERS

3.1 INTRODUCTION

Cement raw material blasted in the quarry, requires size reduction for further process.

Size reduction is performed in crushers. Crushing is comminution in the coarse range

which process amplified by mechanical advantage is transferred through material made of

molecules that bond together more strongly and resist deformation more than those in the

material being crushed do.

Crushing devices hold material between two parallel or tangent solid surfaces and applies

sufficient force to bring the surfaces together to generate enough energy within the

material being crushed so that its molecules fractured and deformation in each other.

In operation, the raw material is delivered to the primary crusher's hopper by dump

trucks. A feeder device such as an apron feeder and belt conveyor controls the rate at

which this material enters the crusher, and often contains a preliminary screening device

which allows smaller material to bypass the crusher itself, thus improving efficiency.

Primary crushing reduces the large pieces to a size which can be handled by the

downstream machinery.

Figure 3.1: Line 2 crusher

44

3.2 TYPES OF CRUSHERS

3.2.1 JAW CRUSHER

In the cement industry the jaw crusher is in general use due to its relatively simple design

and also to the circumstance that this crusher is manufacturing large units. The jaw

crusher serves mainly as primary crusher. This jaw crusher is one of the 3 crushers used

in LMC Langkawi plant.

The size reduction of the crusher feed is performed between two crusher jaws where one

of it is stationary and the other is moved by toggle pressure. The jaws are lined with

ribbed liners consisting of chill cast or quenched steel.

To crush hard, semi-hard and brittle rocks, ribbed liners are used. The included angle of

the rib amounts to 90-100°. For crushing of coarser and considerably harder rocks, the

Figure 3.2: A jaw crusher

45

ribs should be corrugated. For large and very hard rocks, liners with more widely spaced

ribs are used.

Depending on the size of the crusher feed, the width of the ribs in jaw crushers employed

as primary crushers is 50-150mm. Jaw crushers employed as secondary crushers have ribs

with a width of 10-40 mm. The width of the crusher’s discharge opening is being

measured from the top of the rib of one liner to the opposite notching of the other liner.

When working very hard materials, the ribs generate lateral forces which have a negative

influence on the swing jaw shaft is such cases even jaw liners are preferred.

The greatest wear shoes at the lower part of the fixed jaw plate. The constructional design

of the jaw liners makes it possible to turn over a worn jaw liner 180° so that the worn side

comes upwards. This will make the lifetime of the jaw liner becomes longer.

Figure 3.3: Jaw Crusher with convex-concave shaped crusher plate

46

Double-toggle jaw crusher

In the double-toggle jaw crusher, the movement of the swing jaw is oscillating thus the

crusher feed is being squashed. High compression is applied not only to the crushed

material but also to the crusher jaws. This crusher serves for size reduction of hard and

very hard material in the form of large size rocks.

Single-toggle jaw crusher

In the single-toggle jaw crusher, the motion of the swing jaw is differ from that of the

double-toggle crusher. Here the swing jaw moves not only backwards and forwards but

also up and down. The size reduction is characterized by attrition and squashing.

Compression and friction work simultaneously. This crusher is employed for the

reduction of semi-hard material in smaller feed sizes.

Figure 3.4: Movement of swing jaw Figure 3.5: Schematic of the double-

toggle

Figure 3.6: Movement of swing jaw Figure 3.7: Schematic of single-toggle

47

3.2.2 ROLLER CRUSHER

This is the second type of crusher operating in LMC Langkawi plant. Comminution in a

roller crusher is based on the passage of material between two rotating rolls which crush

the material by compression. The particle size of the crushed material depends on the

distance of both rolls from each other. Depending on the kind of crusher feed, the surface

of the crushing rolls can be smoothed, ribbed or toothed. Subject to the hardness of the

crusher feed, the ribs can be arranged along or across to

the axis of the rolls.

In roller crusher, one of the crushing rolls is rigidly

installed in the crusher frame, whereas the other roll

slides horizontally under spring pressure. The elastic

springing on one of the rolls is a safeguard against

unbreakable material.

To prevent friction between crusher feed and the rolls, both crushing rolls have the same

speed of rotation. The drive is off a motor through a V-belt sheave and a gear wheel to the

fixed roll, and through a suitable linkage to the sliding roll.

Figure 3.8: Schematic of a roller crusher

Figure 3.9: 1200tph limestone

crusher

48

3.2.3 HAMMER CRUSHER

The third crusher operating in LMC Langkawi plant, hammer crushers are widely used in

the cement industry. They are used for size reduction of hard to medium hard limestone.

Hammer mills work with reduction ratios as high as 1:60, depending on the crusher feed.

However, this ratio can increase to 1:80. Sometimes the high reduction ratio of hammer

crushers does away with the need for the installation of multi-stage crushing plants.

Generally two types of hammer crushers are manufactured which are single shaft and

double shaft hammer crushers. These crushers work with the impact effect of the

hammers according to the formula for the kinetic energy of impact (P);

Figure 3.10: A hammer crusher

49

Starting from this point the mass of the hammers in hammer mills was reduced to a

minimum while at the same time increasing the velocity v as far as possible. The result

was greater impact force combined with reduced wear.

In both types of crushers, the crusher feed first passes through the upper or primary grid.

This follows preliminary size reduction of the material by the impact hammers. The final

crushing then occurs on the bars of the lower grid. Because of the two grids with different

spacing, the hammer mills can be considered two-stage crushers.

The impact of the hammers upon the crusher feed is not even. This means the load upon

the crusher and the drive motor is not continuous. Massive flywheels are used to stabilize

the operation. The double rotor crusher has separate drive motors for each shaft.

Purpose Crushing material

Type Hammer Crusher

Processed Material Limestone

Size of Processed Material 1200 mm maximum

Capacity 850 tph

Rotor Speed 185 rpm

Number of Hammer 84

Power Consumption 850 kW

Table 3.1: Information on Hammer Crusher Used in Lafarge Limestone Quarry

50

3.3 PREVENTIVE MAINTENANCES

3.3.1 MODIFY SCRAPER OUTLET OF JAW CRUSHER

Problem

The clay comes in clots block the rollers from keep rotating and functioning.

Solution

Enlarge the scraper outlet chute.

Procedures

1. Power 21602, 21603 and 21604 are isolated.

2. The chute plate is cut out.

3. The crusher casing is cut out.

4. A new plate is fabricated.

5. The new plate is welded to the crusher.

6. New paint is painted on the crusher plate.

7. Test run is done.

8. Housekeeping the work area.

9. The power is connected back.

51

Figure 3.11: Power is isolated and

LOTOTO is applied

Figure 3.12: Chute plate is cut out

Figure 3.13: Chute casing is cut out Figure 3.14: A new plate is fabricated

and welded to the chute

Figure 3.15: The new plate is painted

nicely Figure 3.16: Housekeeping the work

area

52

3.3.2 CHANGE THE TEETH OF JAW CRUSHER

Problem

The continuous operation will cause the wear of rollers’ teeth thus the efficiency of the

crusher has decreases.

Solution

The teeth of the rollers need to be changed with the new teeth.

Procedures

1. Power of the rollers is isolated.

2. The dust on the rollers needs to be cleaned.

3. The teeth that have wear is welded and replaced.

4. The power is turned on again and the rollers can continue its operation.

Figure 3.17: A wear roller Figure 3.18: A cleaned roller

Figure 3.19: New teeth welded

53

CHAPTER 4: GRINDING MILLS

4.1 INTRODUCTION

Grinding mill is a unit operation designed to break a solid material into smaller pieces.

There are many different types of grinding mills and many types of materials processed in

them. Historically mills were powered by hand, working animal, wind or water. Today

they are also powered by electricity.

The grinding of solid matters occurs under exposure of mechanical forces that trench the

structure by overcoming of the interior bonding forces. After the grinding the state of the

solid is changed: the grain size, the grain size disposition and the grain shape. In Lafarge,

vertical and ball mills are used.

Figure 4.1: Grinding mills

54

4.2 VERTICAL MILL (ROLLER MILL)

4.2.1 INTRODUCTION

Roller mills belong to the group of vertical mills and are particularly suitable for the

grinding of medium-hard to soft minerals. They can, however, also be used for the

grinding of comparatively hard substances.

To increase the retaining time of the material on the grinding bowl and improve

the structure of the bed of material, the roller path is designed in the form of a double

groove. The different radii of the grinding elements have a great influence on the way the

material is drawn under the rollers. Besides, this design also ensures the specific energy

consumption remain practically constant in spite of the increasing wear. The grinding

force is distributed to match the wear and ensure maximum utilization of the roller path.

Figure 4.2: Vertical mill

55

4.2.2 MECHANISM

The material to be ground is fed to the roller mill via a flow-regulating device and a feed

chute. It drops directly onto the center of the grinding bowl and for commination is

carried under the roller by the rotation of the bowl. Due to the exerted centrifugal force,

the crushed material is flung outwards over the edge of the grinding bowl and entrained in

the stream of gas from the nozzle ring. All of the material ejected from the grinding bowl

or a certain portion of it is carried in the gas stream to the dynamic separator located

above the grinding chamber. The separator classifies the material entrained in the gas

stream into finished product and oversize. The oversize material falls back onto the center

of the grinding bowl while the finished product is carried by the gas stream to the dust

collector where it is precipitated.

Figure 4.3: Process in vertical mill

56

4.3 BALL MILL (TUBE MILL)

4.3.1 INTRODUCTION

Ball Mill is a cylindrical device used to

grind or mix materials like raw materials

and clinker. The ball mill is an equipment to

grind the crushed materials and carrying on

the smashing again to obtain the desired

particle size.

Consist of several parts which are charging, discharging, cyclone and rotation part, the

ball mill is used in dry and wet material. Hollow axis is made of steel parts with lining

replaceable. It rotates around a horizontal axis, which partially filled with the material to

be ground plus the grinding medium, media. Different materials are used for media

including ceramic balls, flint pebbles and stainless steel balls. In LMC Langkawi, the

various sizes of stainless steel balls are used to grind the raw material.

Figure 4.5: Stainless Steel Used As

Media Figure 4.6: Intermediate Diaphragm

Figure 4.4: Ball mill

57

4.3.2 MECHANISM

Materials shall be evenly charged through quill shaft in feeding device into the first

chamber, which has step or waved lining with steel balls in different specifications. Steel

balls are taken to a certain height by centrifugal force from drum rotation and then fall.

Thus it will give a heavy blow to materials, playing a role of grinding. Materials after

crushed in the first bin shall enter bin across single-layer diaphragm into the second,

which is provided with flat lining with steel balls, to go through further grinding. Powder

shall be discharged from discharging grating, ending the milling process.

Figure 4.8: Shell Liner (side

view) Figure 4.9: Shell Liner (top

view)

Figure 4.7: Inside the ball mill

58

4.4 GRINDING AID

Grinding aids are materials which facilitate grinding in ball or vertical mills by

eliminating ball coating or by dispersing the ground material. When grinding cement, the

additive must also have been shown not to be harmful to the finished cement.

Grinding aids may be added in solution, as solids to the mill feed or directly to the mill

itself.

The addition of a fluid may be more readily controlled than the additional of a small

amount of granular material. Grinding aids are metered in quantities from 0.006% to

0.08% of the clinker weight.

The majority of grinding aids are substances which become strongly absorbed by the

ground particles, so that surface energy requirements are satisfied and no bonds remain to

attract other particles and cause agglomeration.

Figure 4.10: Grinding aid is pumped to the mill

59

4.5 PREVENTIVE MAINTENANCE

4.5.1 OUTER SLOTTED PLATE RENEWED

Procedures

1. Power is isolated and LOTOTO is applied.

2. The manhole mill inlet is opened.

3. The old slotted plate is cut out by cutting bolt.

4. By using a forklift, the new slotted plates are lifted to the floor mill.

5. A chain block is used to lift the plates into mill.

6. Steps 3 to 5 are repeated for each of the new plates.

7. Iching mill is done for the next slotted plate.

8. The housekeeping is done on the work area.

9. Power is connected back and test run is done.

Figure 4.11: Manhole mill inlet

Figure 4.12: Liners are cut out

60

4.5.2 FEED END LINER AND SHELL LINER RETIGHTEN

Problem

There are loosening bolts and missing bolts at Cement Mill 4. Besides, the old shell liners

also need to be replaced.

Solution

The loosening bolts are retightened and the missing

bolts are replaced with the new one.

Procedure

1. Power is isolated and LOTOTO is applied.

2. All the end liners are retightened.

3. If there is a missing bolt, a new bolt needs to

be fixed.

4. If necessary, iching mill is conducted.

5. Steps 2 to 4 are repeated.

6. Safety precautions; extra precautions need to

be taken when lifting the bolt as it is heavy.

7. Use scaffolding is necessary.

8. Housekeeping the work area.

9. Power is turned ON and LOTOTO is removed.

10. Steps 2 to 9 are repeated for the shell liner.

Figure 4.14: Details are needed to be

written at the tag

Figure 4.13: Locked out, Tagged Out,

Try Out (LOTOTO)

61

4.5.3 ALIGNMENT MOTOR FOR DRIVER RAW MILL 2

Problem

The high vibration is detected at the driver for Raw Mill 2.

Solution

Motor alignment need to be done in order to prevent the motor from being damaged and

the shaft may be broken. Other than that, the vibration of the motor also can be reduced.

Procedure

1. LOTOTO is applied.

2. Safety corner is unlocked and opened.

3. The coupling bolt is jacked by a Jacker.

4. Motor bolt is opened.

5. Do alignment for the motor.

6. Tighten back the motor bolt.

7. Fix back the coupling bolt.

8. Close the safety corner.

9. Tighten the bolt of the safety corner.

Figure 4.15: Motor alignment is done

by a qualified engineer

62

4.5.4 TAKING FLOW RATE READING OF GRINDING AID FOR CEMENT

MILL 3 (CM3)

Problem

During the inspection, it was found that some coatings occurred at the inlet pipe of the

solution

Solution

In order to free the coatings, the pipe is knocked

several times. After that, the flow rate is calibrated

again.

Procedure

1. Pipe transferring the grinding aid is knocked

several times to release the coating.

2. Valve at the pipe transferring the grinding aid

from pump into the mill is opened.

3. By using a stopwatch, time taken for beaker to be filled with 1 Liter is recorded.

4. Steps 2 and 3 are repeated till the required

flow rate is achieved.

Figure 4.16: Cement Mill is

inspected by an

engineer

Figure 4.17: Time taken for grinding aid

to achieve 1 Liter is taken

Figure 4.18: Measuring tube used to

measure the volume of

grinding aid

63

CHAPTER 5: DUST COLLECTOR

5.1 INTRODUCTION

Dust is the primary emission in the manufacture of cement. For the control of dust,

Lafarge employs mechanical collectors, from cyclone collectors to a much smaller size

like gravity settling chambers, fabric type dust collectors, gravel bed filters and finally

electrostatic precipitators. To meet the emission standards, combinations of various

collectors are employed, depending on the intensity and temperature of the effluents.

Dust collectors are evaluated by their efficiencies. The efficiency of dust collector

equipment is the ratio of the quantity of precipitated dust to the total quantity of dust

introduced into the collection device expressed in percentage.

Figure 5.1: Dust collection system in LMC Langkawi

64

5.2 TYPES OF DUST COLLECTORS USED IN LAFARGE LANGKAWI PLANT

5.2.1 GRAVITY SETTLING CHAMBERS

Gravity settling chamber is used for pre-cleaning of high dust laden gases. The chamber

works on the principle of removing the dust by reducing the velocity of the gas or air

stream. The gas is directed from the dust generating equipment into the large volume

settling chamber where velocity drops low enough to let large dust particles drop out by

gravity. Dust settling chambers are equipped with deflectors in order to change the

direction of gas flow and so to shorten the settling path of the particles, improving

collection efficiency. However, only relatively coarse particles are removed. For

removing of fine dust particles for instance in the range of 20 microns, large settling

chambers are required.

Technical Data

Efficiency : 30% – 70%

Gas Velocity : Not exceed 0.5 m/sec

Pressure drop : 5 – 25 mm W.G

65

5.2.2 CYCLONES

Cyclone consists essentially of two sections

which are a cylindrical and a conical one. At

the top of the cylindrical section the gas enters

tangentially and spirals along the walls

downward into the conical section. Then, it starts to occupy the center space of the

cyclone and spirals upward to the outlet thimble.

Centrifugal forces push the dust particles towards the wall where they accumulate and

descend down by gravity. Most of the particles fall down to the bottom into a hopper

where the particles are removed by rotary valves or screw conveyors.

In plant, cyclones are used for application with rotary kiln, clinker coolers, crushers,

dryers, grinding mills, conveyor and others. It can be designed for high throughput and

medium efficiency and medium pressure drop as well as for medium throughput, higher

dust collection efficiency and a higher pressure drop.

Technical Data

Diameters : 300 – 2300 mm

Efficiencies : 96.7 %, 92.6 %, 88.2 % and 57.5 %

Temperature : Up to 975 °C

Pressure drop : 30 – 165 mm

Gas throughput: 17 m3/min (1 cyclone) – 8500 m

3/min (6 cyclones)

Cyclone

Figure 5.2: A cyclone

66

5.2.3 MULTIPLE CYCLONES

Multicyclones are enclosed units and arranged in banks for parallel flow with feed gas

from a plenum chamber and with a common dust discharge hopper. Multicyclones units

can operate up to 400 individual cyclones.

In countries with less stringent air pollution regulations, the Multicyclones is in the

cement industry a major component in collection of dust from kiln gases, grate clinker

coolers, dryers and grinding mills. However, in countries with stricter dust control

regulations, the Multicyclones serve mostly as a primary dust collector ahead of high

efficiency dust collectors.

Technical Data

Efficiency : 85 % – 94 %

Diameter : 15 – 20 micron diameter

Pressure drop : 130 mm – 180 mm

Figure 5.3: A multiple cyclone / multicyclone

67

5.2.4 FABRIC FILTERS

Fabric filters are woven or felted cloth made

from natural or synthetic fibers. Fabric filters

can handle small particles in the submicron

range at high efficiency. Depending on the type

of fabric, the filters can withstand temperature

up to 285 °C.

The dust laden gases flow through a porous

medium of the filter fabrics and deposits particles in the voids. After filling the voids, a

cake starts to build up on the fabric’s surface which does most of the filtering. During the

precoating period which lasts only moments, the efficiency may drop. When the dust

layer on the fabric becomes too thick, an increase in pressure drop results thus requires

cleaning of the fabric.

Cleaning is accomplished periodically mostly response to a timer. During cleaning action

there is no air flow through the filter bag in the normal direction thus requires the

particular dust collector compartment must be taken off-stream.

Air bag fabric filter

Cage of the fabric filter

Figure 5.4: A fabric filter bag

Figure 5.5: A fabric filter bag with its cage

68

Cleaning Method

a. Bag swinging

This method imparts a gentle oscillating motion to the tops of the filter bags thus help to

dislodge the dust cake.

b. Reverse air

This method collapses the filter tube by differential air pressure thus releasing the filter

cake.

c. Pulse pressure

The plenum chamber of the isolated compartment is supplied with a burst of compressed

air. This pulse of air expands rapidly and sets up a shock wave.

d. Sonic cleaning

This method employs sound generators which produce a low frequency sound, causing

the filter bags to vibrate. These vibrations combined with reversed air loosen dust

particles from the surface of the fabric.

Figure 5.6: A pulse pressure fabric filter

69

5.2.5 ELECTROSTATIC PRECIPITATORS

The principle of this type of dust collection is based on the utilization of the effect of gas

ionization in a strong electric field which is formed by discharge electrodes and collecting

electrodes.

With a sufficiently high electrical voltage

between two electrodes, the discharge

electrode begins to emit electrons resulting

in charging the gas molecules surrounding

the electrode in positive and negative ions.

Under the influence of the strong electric

field, the negative ions migrate to the grounded positive or collecting electrode. If the gas

is dust laden, the negative ions impose their charge onto the dust particles which then are

attracted by the positive electrode.

By rapping or vibration, the collected dust is removed from the collecting electrode,

dropping into a dust bin. However, a small part of the dust particles will also be charged

positively and precipitate on the discharge electrode. Therefore for cleaning, the

discharge electrode must also be rapped.

Technical Data

DC voltage : 40 – 80,000 V

Efficiency : 85 % - 90 %

Temperature : 200 °C – 250 °C

Pressure drop : 15 mm – 20 mm

Figure 5.7: An Electrostatic Precipitator

70

5.3 PREVENTIVE MAINTENANCE

5.3.1 CHANGE THE AIR BAG FILTER FOR CEMENT MILL 3 (CM3)

Fabric filtration has been applied for many years before. In essence, a dust bearing gas is

intercepted by a permeable fabric in such manner that all the gas passes through the fabric

whilst the dust impinges on the fibre of the fabric and is thereby retained.

Problem

The increases of emission level are caused by

broken filter bags. Besides, the increase of

emissions also can be caused by leaks in the

tubesheet or internal chambers. For this case, the

air filter bags are broken thus the dust cannot be

fully trapped.

Solution

The broken filter bags need to be replaced with the new filter.

Procedure

1. Power is isolated and LOTOTO is applied.

2. Check for the damaged air bag filter.

3. The broken filter bags are replaced with the new

one.

4. Housekeeping the work area.

5. Turn back the power ON and test run the system.

Figure 5.8: Damaged filter bags are

gathered at one place

Figure 5.9: Dust collector

at CM 3

71

5.3.2 INSPECTION AT COM2 DUST COLLECTOR SYSTEM PURGING AIR

In dust collector system, air is purged to filter bags at 6 mbar to make dust in the filter

bags drop. However, low pressure will cause the dust does not drop and this will damage

the filter bags.

Problem

A weird sound is detected when air is purged in the dust collector system.

Solution

An inspection is done to find the source of the weird sound. The inspection needs

Maintenance Department engineers and Process engineers to work together in order to

run this inspection.

Result

It is found that the weird sound comes from the broken nuts of the dust collector. Besides,

it also found that some leakages occur and purging air system is damaged.

Leakage

Figure 5.10: A leakage is found Figure 5.11: Inside the dust

collector

72

CHAPTER 6: PREHEATER

6.1 INTRODUCTION

Preheater is a device used to heat air before the air is used for another process. With the

primary objective to increase the thermal efficiency, preheater recovers the heat from the

boiler flue gas by reducing the useful heat loss. As a result, the flue gas is also sent to the

flue gas stack at low temperature thus allowing the simplified design of the ducting and

the flue gas stack. It also allows control over the temperature of gases leaving the stack.

There are six standard Dry-process kiln system configurations used in high industry

especially for cement production. The all 6 kiln systems are as below;

a. Suspension Preheater Kiln

b. In-Line Calciner using Excess air

c. In-Line Calciner

d. Separate Line Calciner-Downdraft

e. Separate Line Calciner

f. Separate Line Calciner with In-Line Calciner

Figure 6.1: Preheater towers

73

6.2 MECHANISM

Figure 6.2: Temperature preheater LK2

Multi-Stage Cyclone Preheater

Modern cement manufacturing plant like Lafarge preheats raw meal to calcination

temperature in a multi-stage cyclone preheater. Most of the calcination process takes

place in a separately fired, stationary calciner, while the remaining calcination and

clinkerization process takes place in a rotary kiln.

Raw meal is introduced at the inlet gas duct to the Cyclone I. It is subsequently preheated

by hot, countercurrent gas flow as it is continuously collected and passed down the other

cyclone stages in the preheater to the calciner. Fuel is burned in the calciner to achieve

92-95% of the total material calcination before collection in the bottom cyclone and

entrance into the kiln.

74

Combustion air

Combustion air for the calciner is taken from the kiln via the riser duct and through a

separated tertiary air duct from the cooler. Compared with other conventional preheater,

it’s a very uncomplicated and effective way for FL Smith’s preheater used by Lafarge to

create low NOx emissions with only one firing location, one meal split and one tertiary

air stream entering tangentially to the calciner as the preheater design is based on dividing

the meal from the second-lowest stage cyclone to the kiln riser and the calciner. These

feed points are separated by an expanded riser duct that forms a NOx reducing zone. That

is, the calcining chamber is built into the kiln riser. All of the calciner fuel is introduced

to the kiln riser duct with less oxygen than required for complete combustion, thereby

forming a reducing atmosphere.

Above the reduction zone is the main calciner vessel, which is divided into two or more

sections separated by a notch. The changes in cross-sectional areas create turbulence that

ensures effective mixing of fuel, raw meal and gas, improving heat transfer and

combustion. The calciner outlet loop duct ensures optimum gas retention time, further

mixing and complete fuel combustion section of the calciner. This creates a “hot zone” in

the lower section of the calciner that is conducive to burning difficult fuels and further

NOx reduction.

Combustible waste

Used car tyres and wood chips are used as partial substitution for ordinary types of fuel as

they contain no chemical compounds that might damage clinker quality or affect kiln

operation. Such fuels are normally fed into the kiln riser for subsequent complete

combustion at the kiln inlet.

75

Figure 6.3: Parts of preheater

76

6.3 PREVENTIVE MAINTENANCES

6.3.1 MEASURING TEMPERATURE AND PRESSURE READING

In preheating process, the material will be fed on the top of the preheater and fell into the

ground. In the process of material flows from the top to the bottom, the material will

experience the increase of temperature from as low as 300°C to 1000°C. In order to

maintains an efficient process, temperature, pressure, oxygen and carbon monoxide

readings are taken. This will help engineers to detect if any problem occurs.

Equipments that have been used are digital thermocouple, manometer and Flue Gas

Analyzer. Besides, the tools are steel rod and Pitot tube.

Figure 6.6: Thermocouple

Figure 6.4: The amount of oxygen is

measured by a Fluid Gas

Analyzer

Figure 6.5: Manometer used to

measure pressure

77

6.3.2 COATING LEAKAGE AT SINGLE FLAP DAMPER, HOT MEAL DUCT

Problem

There is a leakage identified at each of the flap damper, Hot Meal Duct in Preheater Line

2 (LK2). The leakages occur at the bearings of the damper.

Implications

The leakage allows fresh air flowing inside the preheater thus affecting the heating

process. If this problem keep occur, it may cost lot to plant as more fuel is needed in keep

maintaining the required heating temperature.

Solution

As the flap damper keep moving, normal glue cannot be used. Thus, silicon glue has been

used to cover the leakages. The ductility of the silicon glue after it dries make it the most

suitable glue to be used to encounter this problem.

Figure 5 A flap damper

Silicon Glue

Figure 6.8: Leakage has been blocked

Figure 6.7: Flap damper

78

6.3.3 TAKE PRESSURE, TEMPERATURE AND AIR FLOWS OF KILN

There are 3 types of flows that have been

calculated which are axial, swirl and coal. All

these flows have been measured its pressure.

It is a need to measure the pressure,

temperature and air flows as this helps

engineers especially for Process Engineers in

determining the exact shape of burning flame

generated in kiln. The correct shape of

burning flame produced will cause an

efficient burning process in kiln thus high

clinker quality and optimum power

consumption can be achieved. The desired

flame for burning is the compact medium-

length flame. In order to obtain the shape,

magnitude of swirl and axial flow need to be the same.

Figure 6.10: A rotating kiln

Figure 6.9: Temperature is measured

by a thermoscan

Figure 6.11: Type of flames in rotating kiln

79

6.3.4 MEASURING THE WET BULB TEMPERATURE

Wet bulb temperature indicates the humidity of air. This temperature indicated by a

moistened thermometer bulb exposed to the air flow. The wet bulb temperature can be

measured by using a thermometer with the bulb wrapped in wet muslin. The rate of

evaporation from the wet muslin on the bulb, and the temperature difference between dry

bulb and wet bulb depends on the humidity of air.

Procedure

1. Coat the wet muslin at the sensor of thermocouple.

2. With half minute intervals, the temperature reading is noted.

3. As the temperature constant, the wet bulb temperature is obtained.

Figure 6.13: Muslin is wet by water

Figure 6.12: A muslin is tied up at thermocouple

80

CHAPTER 7: QUALITY CONTROL

7.1 INTRODUCTION

In the manufacture of cement, proportioning of raw materials is strictly controlled at all

stages to ensure the quality of product well exceeds the quality requirements stipulated in

the relevant standard specification, ISO 9000.

Besides, researches and various tests are keep doing by the Quality Control Team in order

to keep and at the same time enhancing the quality products ordered by customers. Any

complaints regarding to their products are taken serious and further inspections are done

to find the main cause of the problem so that the same problem will not occur again.

ISO 9000

ISO 14001

OHSAS 18001

Figure 7.1: Qualifications obtained by Lafarge Malayan Cement

81

7.2 HARD GRAIN INDEX

Hard Grain Index Test is done to ensure the quality of product in term of fineness. Good

quality of product has not too large nor too small. Good fineness product will provide

cement that will be easily mixed and has great strength.

Step Pictures Descriptions

1

Clinker is filtered until 600 micron clinker is

obtained

2

The clinker then is weighed

3

By using Hard Grove, the clinker is crushed to

small

4

Disc Mill Grinding is used to crush the clinker till

45 micron

5

The index is calculated by using information

obtained

Table 7.1: List of procedures

82

7.3 SIEVE TEST

Sieve test is done in order to determine the size of limestone that has been crushed by

limestone crushers. The appropriate size of limestone is necessary so that the limestone

can be crushed and mixed easily in millers. The most suitable size of limestone for

milling is less than 25mm however limestone size up to 50mm is still acceptable.

Figure 7.2: List of procedures

Samples obtained is filtered by 100mm, 50mm and 25mm

filters

For each of the size obtained, the weight

of it is measured.

The percentage of the weight to the overal weight is calculated

83

7.4 RESIDUE TEST

Residue test is done to ensure the fineness of product that has been produced. This test is

done for both Normal Blaine product and High Blaine product. For Normal Blaine

product, the 2.5g samples is needed while for High Blaine product the 5g samples is

needed.

Figure 7.3: List of procedures

STEP 1

•Normal Blaine product is weighed to the respective weight needed

STEP 2

•The sample then is filtered to obtain 60 micron residue

STEP 3

•The residue is weighed back

STEP 4

•By using formula, the product residue is calculated

84

7.5 DROP TEST

Drop test is a test where the feed rate of each raw materials entering into machines is

calculated. The feed rate is very important in achieving the desired product with optimum

power consumption.

Figure 7.4: List of procedures

STEP 1

• Speed of belt conveyor is measured by a contact tachometer

STEP 2 • Power of the belt conveyor is isolated

STEP 3 • A 1m long is marked on the belt conveyor

STEP 4

• Material in the 1m range is put onto the weigher

STEP 5 • The weight of material is recorded

STEP 6

• By using a formula, the feed rate is calculated

85

CHAPTER 8: PROJECTS

8.1 SEALING AIR FAN FOR CEMENT MILL 4

8.1.1 BACKGROUND

This project covers the following scope of works:

To purchase and install one unit air sealing fan complete with accessories (filter, ducting

etc) to prevent dust from entering into Cement Mill 4 (CM4) combiflex system.

LANGKAWI PLANT CM4 DATA

Cement mill no. 4 (CM4) was commissioned by Krupp Polysius AG in 1997. The mill

that has shell diameter 5200 mm and nominal length 15,000 mm is driven by 2 units of

gear box supplied by Flender AG. In the combiflex system (consist of gear box, girth gear

and supporting equipment) the lubrication oil is sharing between gear box and girth gear

by means of one LO unit system.

Since commissioned, the gear box had been overhauled a few times due to high vibration

as follows:

Year overhauled Reason

Nov 2007 High Vibration

May 2008 Output shaft bearing damage

Aug 2009 Input shaft crack – Total Overhauled (CAPEX)

May 2010 High vibration (Gear Misalignment)

May 2011 High vibration (CAPEX)

Jan 2012 Gear box replaced (CAPEX)

Table 8.1: Maintenance done for Cement Mill

86

After some various brain storming sessions with Lafarge Malayan Cement engineers, dust

ingression into gearbox oil circulation system was shortlisted as one of the main factors

causing the failure. In addition to precautions of reducing suspended dust and improved

lubrication filters, it was decided to incorporate positive pressure dust suppression

systems in gear-gearbox guard sealing.

On most occasions, the Combiflex arrangement is at the mill feed end making the

Combiflex system highly vulnerable to dust contamination. The ingress dust through seal

combines with oil to form clots at the lubrication nozzles for mesh lubrication and bearing

lubrication resulting in lubrication and gearbox components failure. Due to dynamic

application of seal, 100% theoretical sealing of dust ingress is not possible. Additionally,

the abrasive nature of clinker dust in the inlet aggravates the situation further.

The only way to effect 100% sealing from dust ingress in Combiflex system is by

creating a positive air pressure inside the combined gear and gearbox guard. This can be

achieved by installing low pressure high volume blower (forced draft) with discharge

connections directly into the common guard seal areas. The blower inlet is mounted with

suction filter which is regularly cleaned. The individual pipes branching off to the guard

are to be mounted with flow adjustment dampers. This will help in ensuring uniform flow

of air in all sealing areas.

This main objective of this project is to sustain Cement Mill 4 operation and improve mill

reliability by securing CM4 operation from major failure caused by gears damage due to

oil contamination.

87

8.1.2 OBJECTIVE

This main objective of this project is to sustain Cement Mill 4 operation and improve mill

reliability.

8.1.3 EXPECTED BENEFITS

Main benefit is to secure CM4 operation from major failure caused by gears damage due

oil contamination.

8.1.4 COST JUSTIFICATION

The justification for installation of sealing air fan is Strict Sustaining Capital as this work

is essential to sustain the operation of Cement Mill no 4 (CM4). The project cost can be

justified based on loss of maintenance cost due to gearbox repaired as follows

No Equip Year

Overhaul Duration

(day)

Cost (RM)

Specialist Contractor Rental Spare part

Total

1 CM4-No 2

2008 May 14 250000 100000 N/A 150000 500000

2 CM4-No 1

2007 November

15 150000 100000 60000 150000 460000

3 CM4-No 1

2009 August

23 250000 100000 85000 850000 1285000

4 CM4-No 2

2010 May 14 150000 108000 25000 200000 483000

GRAND TOTAL 2,728,000

For year 2011, CM4 mill inlet lubrication oil had been renewed 4 times due to oil badly

contaminated which cost of RM 140 000.

Table 8.2: Project cost justified based on loss of maintenance cost

88

8.1.5 RESOURCE REQUIREMENTS

Budget

Total estimated investment of RM 262,500.00 is required for this project to be

implemented.

The details breakdown of the budget is as follows:

No Part Description Cost (RM) Remark

1 Sealing air fan (1 unit) 40,000 Quotation

2 Air filtering chamber 30,000 Estimation

3 Ducting and other accessories 80,000 Estimation

4 Electrical parts 20,000 Estimation

5 Contractor for installation 80,000 Estimation

6 Contingency cost (5%) 12,500

TOTAL 262,500

Table 8.3: Detail breakdown

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8.2 TRACING PRESSURE VESSEL TANK IN CEMENT MILL SECTION

8.2.1 INTRODUCTION

In manufacture of cement, the usage of compressed air is very important. The compressed

air is used by almost all parts available in plant especially machines. In Lafarge Malayan

Cement Langkawi Plant, compressed air is generated by 6 units of compressor located in

Silo 4 and Silo 5. From the Silos, the compressed air is flowed to each of the sections in

plants and it then will be distributed to each of parts and machines needed by pressure

vessel tank.

Pressure vessel tank is a closed container designed to hold gases or liquids in transferring

compressed air throughout the entire sections in plant. As pressure may drop when

flowing throughout the system, the pressure vessel tank is important in keep maintaining

the required pressure needed thus machines can keep operating with suitable pressure.

Figure 8.1: A pressure vessel

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8.2.2 PROBLEM

Damages and malfunction of pressure vessel tanks may cause disruption on operating

machines like millers, grinders and dust collectors. Moreover, a long period taken to trace

and repair the damage pressure vessels may cause the damages of machines plus

unavoidable accidents like pressure vessel tank explosion to occur. This might seem to be

a simple problem however if the problems occur, it might cost lot to plant.

8.2.3 SOLUTION

In order to solve the problems, an initiative to trace each of the pressure vessels in

Langkawi plant is started by Process Department and well supported by LMC Langkawi

Safety and Health Department.

Each of the pressure vessel tanks is traced and the condition of each tanks are remarked in

a proper document for official reference later on. For more easily, a diagram indicates all

tanks available in Cement Mill Sections are drawn. This helps engineers to know where a

pressure vessel tank is located if problems occur.

The official reference document and drawing are attached in Appendix.

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Figure 8.2: Drawing of Pressure Vessel Tanks for Cement Mill 4

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8.3 MEASURING THE ACTUAL FAN PERFORMANCE CURVE FOR LK1 AND LK2

8.3.1 INTRODUCTION

Since each type and size of fan has different characteristics, fan performance curve must

be developed by the fan manufacturers.

A fan performance curve is a graphical presentation of the performance of a fan. Usually

it covers the entire range from free delivery (no obstruction to flow) to no delivery (an air

tight system with no air flowing). Generally, these curves are determined by laboratory

tests, conducted according to an appropriate industry test standard, and obtained under

ideal conditions.

The fan curves used to predict the pressure-flow rate performance of each fan. With the

curve also, engineers can determine which fan gives the volumetric flow rate needed for

their system pressure drop. In additions, engineers also can choose fan that has its peak

efficiency at or near to their operating point.

For this special task, I was asked to calculate the actual fan performance curve for Raw

Mill EP fan in Line 2 and Cooler Exhaust Fan. The produced curve will help engineers at

Process Department in analyzing the actual performance at the existing fan thus can

identify and overcome problems occur.

Formula that has been used;

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8.3.2 LK2 – RAW MILL EP FAN

Figure 8.3: Raw Mill EP fan curve

Figure 8.4: Performance Curve plotted for RM EP Fan

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8.3.3 LK2 – COOLER EXHAUST FAN

Figure 8.5: Cooler Exhaust Fan curve

Figure 8.6: Performance Curve plotted for Cooler Exhaust Fan

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8.3.4 DOPOL WASTE GAS FAN

Figure 8.7: Dopol Waste Gas Fan curve

Figure 8.8: Performance Curve plotted for Dopol Waste Gas Fan

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8.3.5 RAW MILL FAN

Figure 8.9: Raw Mill Fan curve

Figure 8.10: Performance Curve plotted for Raw Mill Fan

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CHAPTER 9: DISCUSSIONS

9.1 SAFETY AT WORKPLACE

Heavy industries may be a great place to work and earn big salaries however with the

speeds in which events occur mixed with the sum of possible safety hazards, it might be

our own grave.

The Main Dangers at Work Place

Dangers are elsewhere in the site of heavy industries. Dangers could come from our own

negligence, others’ negligence or the condition of the site itself. It can be avoided if all

site hazards are well avoided and safety precautions are seriously taken.

The top hazards recorded in heavy industry are as follows:

1. Trip and fall

This item always makes the top of the list for heavy industry site hazards. Falls from

equipment, scaffolding, and other high places are dangerous and far too common to

occur.

Figure 9.1: Signs of hazards

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2. Scaffolding

This also causes falls and if put together improperly can cause injuries and death. People

seldom think about heavy industrial equipment safety with respect to equipment that

moves but standstill equipment can be just as dangerous when not used properly.

3. Electrical appliances

This hazard involves all the electrical appliances used seldom in site. Explosion, electrical

shock or electrocution may occur on these appliances if it is not well maintenance. If this

occurs, serious injury and fatality may occur. To prevent this from occur in their

workplace, continuous inspection need to be executed to all electrical appliances used in

their site.

4. Over-exertion and stress

This repetitive use injury has been recorded as the fastest growing type of injury in the

workplace. It is caused by repeating the same actions or maintaining the same position for

a long time. The effects of this problem are unconscious and injuries at wrist hand or

back.

5. Excessive Noise

Most of heavy industries workers are exposed to excessive noise that comes from

operating machines. The louder the noise, the more damage it can cause. The excessive

noise may cause permanent injury like hearing loss either progressively, or by the

exposures over a long period of time. To overcome this, workers need to wear ear buds

when working in a noise site.

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9.1.1 PERSONAL PROTECTIVE EQUIPMENT (PPE)

PPE which stands for Personal Protective Equipment is defined as equipment which is

intended to be worn or held by a person at work and it protects him against one or more

risks to his health or safety.

Figure 9.2: Basic Personal Protective Equipments

Employers have basic duties concerning the provision and use of personal protective

equipment (PPE) at work and they have no right to ask for money from an employee for

that equipment, whether it is returnable or not. If employment has been terminated and

the employee keeps the PPE without any permission, as long as it has been made clear in

the contract, employer may be able to deduct the cost of replacement from any wages

owed.

To allow the right type of PPE to be chosen, employer need to be carefully consider the

different hazards in the workplace. This will enable them to access which type of PPE are

suitable to protect them against hazard for the job need to be done.

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9.1.2 SAFETY REPORTING SYSTEM (SRS)

Safety Reporting System (SRS) is an online database which allows members of Lafarge

to share and learn effective and efficiently and at the same time follow up the corrective

actions. Analysis of accident is circulated on weekly basis to all employees throughout

the organization worldwide.

For this reporting system, each members of Lafarge Cement is needed to submit at least 2

reports on any near miss or faulty observed in plant. The report shall be based on

members of Lafarge, contractors, or the plant condition itself which if it is continually

ignored will cause accidents later on.

The structure of the report will be picture of the situations, who involve, time taken, the

location and lastly the estimated cause if it happens. The report then will be sent to the

Safety and Health Department via Lafarge e-mail and it will be strictly checked and

recorded by the department.

To encourage members of Lafarge Cement to join this program and send more reports

monthly, a reward system has been introduced. In this reward system designed by Safety

and Health Department, members who recorded to send higher than 2 reports will be

rewarded with a voucher. This RM50 voucher can be used by members to buy any items

at Teow Soon Huat Shopping Mall located in Kuah, Langkawi.

This reward system has encourages Lafarge members to submit more reports thus

indirectly increases the awareness on the important of safety and hazards at the workplace

amongst them. With the increasing number of report submitted by members compared to

the last few years, the objective is totally achieved.

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9.2 ENVIRONMENTAL ISSUE

9.2.1 LAFARGE GROUP POLICIES

For Lafarge Cement Group, they keep believe that they will only succeed in the long term

if their actions respect the common interest. This means they must not comply with laws

but also conduct business consistent with sustainable development principles. Thus, they

are committed to the protection of the environment, human health and well-being, to the

migration of climate change and the conservation of nature.

With objective of to ensure the continued improvement of environmental performance,

they aim to use energy and natural resources more efficiently, minimize the production of

waste, harmful air emissions, and water discharge while seeking ways to preserve

landscape and biological diversity.

In order to implement these objectives, Lafarge commits to:

1. Operations

Operate their facilities in a manner that meets local laws, standards and

regulations and the environmental management systems requirements.

Minimize the use of non-renewable resources (feasible and safe) and replace them

with substitute raw materials (alternative fuels or biomass).

Minimize the amount of hazardous and other wastes generated, reuse and recycle

materials where practicable and dispose of wastes using safe and responsible

methods.

Implement programs to prevent accidental releases like having emergency

response action programs in place at all sites.

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2. Resources, Training, Research

Provide adequate financial and human resources, employee training and

awareness rising to facilitate continuous improvement in environmental

performance.

Take the necessary steps, including sponsoring research, to improve employee’s

knowledge of the environmental impacts of their processes and products.

3. Procurement

Evaluate the environmental values and policies of subcontractor and supplier

candidates as part of the selection process.

Require subcontractors and suppliers to respect our environmental, health and

safety values and comply with Lafarge policies and procedures when present at

plant.

4. Stakeholder relations

Provide stakeholders routinely with environmental information about Lafarge

operations and products in an open manner.

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9.2.2 LAFARGE MALAYAN CEMENT INITIATIVES

Conserving natural resources – Biomass to energy

Objective

To reduce the cement plant’s consumption of fossil fuel and provide a disposal solution

for the organic wastes generated by palm oil production.

Context

Malaysia is the world’s leading producer of palm oil. Waste from this production (mainly

the palm kernel shells) poses a disposal problem for growers, and is commonly landfilled

or burned with no energy recovery. At the same time, the Rawang and Kanthan cement

plants use large quantities of coal which is imported and used as their primary fuel.

Figure 9.3: CO2 emissions from combustion of the biomass

are considered to be “carbon neutral”.

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Solution

Lafarge Cement decided to use palm kernel shells as a secondary fuel in its cement kiln.

The equipment needed to receive, sort and grind the palm kernel shells, as well as the

necessary belt conveyors, was installed. The shells are now fed directly into the

precalciner.

Results

This substitution is a means of reclaiming the biomass for energy at a rate of 10% of

overall energy consumption. By reducing the amount of coal burned, the two plants have

cut their aggregate CO2 emissions by 140,000 metric tons per year, given that emissions

generated by combustion of the biomass are considered “carbon neutral”. Finally, the

reduction in imports also means less transport-related pollution.

Figure 9.4: Palm kernel shells are substituted for some

of the coal.

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Lafarge Roofing – CoolRoof insulating roof system

Objective

To define a construction system appropriate for tropical climates which control heat

transmission from the roof to the living areas of the house.

Context

In warm climates, construction features can make a significant contribution to efforts to

control the indoor temperature of housing units. In conventional construction, the sun’s

radiation on the roof tiles causes heat to be transmitted from the roof to the attic or loft

area, and then down into the living areas. If the house is air conditioned, high

temperatures also have an impact on energy consumption, since more energy is needed to

counterbalance the higher heat load.

Solution

Lafarge developed the Monier CoolRoof, a roofing system that allows a significant

reduction in the indoor temperature of houses. The light color of the roofing tiles limits

Figure 9.5: A conventional roofing system transmits

heat from outside to inside.

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the heat absorption. Heat is then blocked by a reflective aluminum radiant barrier foil

installed below the roof tiles. The warm air around the radiant barrier is then evacuated by

means of an arrangement consisting of a breathable ridge membrane, counter battens and

ridge tiles. Finally, an insulating material limits the transmission of the remaining heat.

Result

Compared to conventional roofing systems, Monier CoolRoof cuts heat transmission by

more than 80%, lowering the building’s indoor temperature by up to 4°C.

Figure 9.6: CoolRoof provides effective insulation and optimizes

air circulation.

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CONCLUSION

Internship program at Lafarge Malayan Cement Langkawi Plant was successfully done.

Throughout the program, a lot of experiences, skills and knowledge had been obtained

either related with engineering or not.

While training there, I was exposed to the real working life in heavy industry. In industry

like cement manufacturer, problems and challenges come in many ways. Executives like

engineers need to think the new solutions for each of challenges come in a very short

period. In order to work in this surrounding, they need to have a strong determination for

them to overcome the working pressure.

Moreover, training at Lafarge also gives me an opportunity to understand and applies all

the things that I have learned at UNITEN. Strong foundation in theories needs to be

obtained in order to understand the working principle of each machine operating in plant.

However, it is not a big problem if our foundation is not too strong as each of Lafarge

members stand on their organization’s principle which is learning is a continuously done.

That is why Lafarge members keep learning by attending seminars and training done by

the head quarter. Helps and explanations will be well delivered to trainees if they not

understand in a particular thing.

Finally, I would like to suggest UNITEN to prolong the industrial training period in the

future as 3 months internship is not sufficient for students to well understand and adapt

things occur in an organization. For Lafarge, it is better if each of trainees there is guided

with a planned schedule so that they know what they will learn thus they can prepare

themselves first. The internship program will be more successful if these

recommendations are done in the future.

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REFERENCES

Books

1. Standard Specification for Portland Cement. Published by the American Society

for Testing Materials. Philadelphia. Pa. USA

2. Sobolewski. 1957. Crushers, Design and Applications. Katowice

3. Der Mechanismus, 1962. Size reduction by impact – Considerations about

performance and sizing of impact crushers, Aufbereitungs-Technik ( p.437-447,

479-490 )

4. 1938. Grinding in Cement Industry Rock Products 1, Rockwood

5. Sullivan. 1927. Passage of Solid Particle Through Rotary Cylindrical Kiln.

Published by US-Bureau of Mines

6. Dersnah. 1956. Ball Coating and Grinding Aids. Published by Portland Cement

Association. Chicago: Illinois

7. Bernutat. P. (1969). Design of Modern Tube Mills and Mechanical Air Separators.

Published by Cement-Wapno-Gips, Warsaw 5 (p.131 – 134)

8. Kannewurf. (1956). Grindability Standard. Published by Portland Cement

Association Report. Chicago

9. Pearson. 1952. Fine Grinding in Tube Mills. Published by Rock Products ( p.106 )

10. Clarke. 1962. Process Engineering Calculations. Published by McGraw – Hill.

New York

11. Tonry. 1961. Heat Transfer Systems for Dry Process Kilns in Cement

Manufacturing. Published by Pit & Quarry. Chicago ( p.151 – 154 )

109

12. 1972. The Development of F.L. Smidth and Co, Published by Cement Technology.

London ( p.14 – 19 )

13. 1983. Pulse Energization of Electrostatic Precipitator of Electrostatic

Precipitators. Copenhagen: Denmark

Websites

1. United States Department of Labor. Confined Space. taken from

http://www.osha.gov/SLTC/confinedspaces/index.html

2. Canadian Centre for Occupational Health and Safety. Confined Space-

Introduction. taken from

http://www.ccohs.ca/oshanswers/hsprograms/confinedspace_intro.html

3. Wikipedia. Confined Space. April 2012. taken from

http://en.wikipedia.org/wiki/Confined_space

4. Binq Inc. Preheater and Calcining System. 2012. taken from

http://www.miningequipments.org/faq/preheater-and-calcining-system/

5. FLSmidth. October 2011. Preheating. Taken from http://www.flsmidth.com/en-

US/Products/Product+Index/All+Products/Cement+Preheating/In

Line+Calciner+Preheater+System/In-Line+Calciner+Preheater+System

6. Wikipedia. Air Preheater. March 2012. taken from

http://en.wikipedia.org/wiki/Air_preheater

7. Magotteaux. Pioneering Solutions. 2010. taken from

http://www.magotteaux.com/wiki-mag/ball-mill/

8. Wikipedia. Ball Mill. May 2012. taken from

http://en.wikipedia.org/wiki/Ball_mill

9. Vipeak. Ball Mill. 2008. taken from http://www.crushingmill.com/ball.html

110

10. ThyssenKrupp Polysius. Raw Material Preparation Brochures. 2010. taken from

http://www.polysius.com/en/publications/brochures/raw-material-preparation/

11. Manufacturing-the cement kiln. Taken from http://www.understanding-

cement.com/kiln.html

12. CIMA. Production Process. 2011. taken from

http://www.cima.com.my/cima/mainpage.php?menu=process

13. Wikipedia. Portland Cement. May 2012. taken from

http://en.wikipedia.org/wiki/Portland_cement

14. CEMBUREAU. Cement Manufacturing Process. taken from

http://www.cembureau.be/about-cement/cement-manufacturing-process

15. Essroc Italcementi Group. Engineering Graduates. 2012.

http://www.essroc.com/default.aspx?pageid=183

16. Lafarge North America. About Cement. taken from

http://www.lafargenorthamerica.com/wps/portal/na/en/2_2_1-

Manufacturing_process

17. Lafarge United Kingdom. All About Cement. 2012. taken from

http://www.lafarge.co.uk/wps/portal/uk/2_2_1-Manufacturing_process

111

Appendix A – SRS RM50 Voucher

112

Appendix B – Worker Pass

(Front)

(Back)

113

Appendix C – Near Miss Report Form

114

Appendix D – Safety Observation Report Form

115

Appendix E – Risk Assessment Form

116

Appendix F – Measurement Overview Sheet for Preheater

117

Appendix G – Cement Mill Lubrication Piping Drawing

118

Appendix H – Shell Liners Arrangement in Cement Mill

119

Appendix I – Purge Air Seal Plan for Cement Mill

120

Appendix J – Type of Shell Liners and Its Arrangement in Cement Mill

121

Appendix K – Drawing Produced for Maintenance Department in Changing New

Shell Liners

122

Appendix L – Traced Pressure Vessel Valve in Cement Mill Section